Battery Charging Device With Segmented Housing

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Solution Overview

Problem

Existing battery charging devices lack effective protection against water and dust, especially when used outdoors under unfavorable conditions, and struggle with heat management during high-power charging modes.

Innovation Solution

A battery charging device design featuring a separately formed electronics housing that is water- and dust-protected, with a thermally decoupled sealing unit, a high-capacity heat transporting element, and a cooling system that includes a fan and airflow routing, ensuring safe operation and efficient heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single integrated housing is used for battery charging devices, then manufacturing is simpler and device complexity is reduced, but protection against water and dust is insufficient for outdoor use

Engineering Contradiction:

Improveprotection against water and dustVSAvoidhousing structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The housing is divided into two separate parts: a battery housing for receiving the battery and an electronics housing for accommodating the power electronics unit. This segmentation allows each housing to be optimized independently - the electronics housing can achieve high protection class (IP67) for water and dust resistance, while the battery housing provides easy access and battery insertion/removal functionality.

Inventive Principle:

Principle #1Segmentation

2Productivity

If high-power charging mode is used to reduce charging time, then productivity is improved, but heat generation increases causing thermal hazards

Engineering Contradiction:

Improvecharging speedVSAvoidheat generation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The sealing unit thermally decouples the battery housing from the electronics housing, creating separate thermal zones. This allows the battery housing to be optimized for heat dissipation while the electronics housing maintains its protection class, preventing heat transfer that could compromise the sealing or cause thermal hazards.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sealing unit acts as a thermal intermediary between the battery housing and electronics housing. It provides mechanical sealing for protection while simultaneously blocking heat transfer, thus mediating the thermal interaction between the two housings during high-power charging operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If cooling elements are integrated into the battery housing, then heat dissipation is improved, but protection class of the electronics housing may be compromised

Engineering Contradiction:

Improveheat dissipationVSAvoidprotection class

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

By separating the battery housing and electronics housing, cooling elements can be integrated into the battery housing without compromising the protection class of the electronics housing. The thermal decoupling through the sealing unit ensures that cooling operations do not affect the sealed electronics compartment.

Inventive Principle:

Principle #1Segmentation

4Reliability

If a separately formed electronics housing is used to achieve water and dust protection, then reliability in outdoor conditions is improved, but manufacturing complexity and device assembly increase

Engineering Contradiction:

Improveoperation in wet conditionsVSAvoidhousing assembly

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The separate electronics housing can be manufactured and tested for protection class independently, then assembled to the battery housing through the sealing unit. This modular approach actually simplifies manufacturing by allowing parallel production of housing components and reducing the complexity of achieving high protection class in a single integrated housing.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a safe and efficient charging solution that can operate in wet conditions and prevents overheating during high-power charging, ensuring reliable battery charging with reduced risk of electrical or thermal hazards.

Implementation Method 1

at least one sealing unit which at least in part thermally decouples the at least one cover body and the principal body

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

at least one heat transporting element which thermally joins the at least one cover body with the power electronics unit

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

the at least one cover body include cooling fins

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 4

the at least one cover body include cooling fins

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 5

at least one fan which is provided to generate an airflow for cooling the electronics housing

Methodology Applied

Scientific EffectForced convection: Forced Convection

Data Source

PatentUS10601236B2Battery charging device

Publication Date: 2020.03.24 ROBERT BOSCH GMBH

AI summary

A battery charging device includes: a battery housing which delimits at least one battery receiving space at least in part; at least one power electronics unit supplying a charging voltage; and an electronics housing which (i) is formed separately from the battery housing, and (ii) accommodates the power electronics unit in at least one of water-protected manner and dust-protected manner.